steering ISUZU KB P190 2007 Workshop Owner's Manual

POWER-ASSISTED STEERING SYSTEM 3B-7
Power Steering System Test
Test Procedure
F02RX002
Legend
(1) Bolt
(2) Hose
(3) Power Steering Unit
(4) Power Steering Pump


The fluid pressure test in the power steering system is
performed to determine whether or not the oil pump and
power steering unit are functioning normally.
The power steering system test is used to identify and
isolate hydraulic circuit difficulties. Prior to performing
this test, the following inspections and corrections, i
f
necessary, must be made.
・ Inspect pump reservoir for proper fluid level.
・ Inspect pump driver gear condition.
1. Place a container under the pump to catch the fluid when disconnecting or connecting the hoses.
2. W ith the engine NOT running, disconnect the
pressure hose at the power steering pump and
install power steering tester 5-8840-0135-0 and
power steering tester adapter 5-8840-2297-0 as
shown in the illustration. The gage must be between
the shutoff valve and pump. Open the shutoff valve.
3. Check the fluid level. Fill the reservoir with powe
r
steering fluid, to the "Full" mark. Start the engine,
then turn the steering wheel and momentarily hold it
against a stop (right or left). Turn the engine off and
check the connections at tester for leakage.
4. Bleed the system. Refer to Bleeding the Powe
r
Steering System in this section.
5. Start the engine and check the fluid level. Add power steering fluid if required. W hen the engine is
at normal operating temperature, increase engine
speed to 1500 rpm.
CAUTION: Do not leave shutoff valve fully closed
for more than 5 seconds, as the pump could
become damaged internally.


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ISUZU KB P190 2007

3B-8 POWER-ASSISTED STEERING SYSTEM
6. Fully close the shutoff valve. Record the highest
pressures.
・ If the pressure recorded is within 9800-10300 kPa
(100-105 kg/cm
2/1422-1493psi), the pump is
functioning within its specifications.
・ If the pressure recorded is higher than 10300 kPa
(105 kg/cm
2/1493psi), the valve in the pump is
defective.
・ If the pressure recorded is lower than 9800 kPa
(100 kg/cm
2/1422psi), the valve or the rotating
assembly in the pump is defective.
7. If the pump pressures are within specifications, leave the valve open and turn (or have someone
else turn) the steering wheel fully in both directions.
Record the highest pressures and compare with the
maximum pump pressure recorded in step 6. If this
pressure cannot be built up at either side of the
power steering unit, the power steering unit is
leaking internally and must be replaced.
8. Shut the engine off, remove the testing gauge.
9. Reconnect the pressure hose, check the fluid level and make the needed repairs.
10. If the problem still exists, the steering and front suspension must be thoroughly examined.

Maintenance
The hydraulic system should be kept clean, the fluid
level in the reservoir should be checked at regula
r
intervals and fluid added when required. Refer to
Recommended Fluids and Lubricants in General
Information section for the type of fluid to be used and
the intervals for filling.
If the system contains some dirt, flush it as described in
this section. If it is exceptionally dirty, the pump must be
completely disassembled before further usage. (The
steering unit cannot be disassembled.)
All tubes, hoses, and fittings should be inspected for
leakage at regular intervals. Fittings must be tight. Make
sure the clips, clamps and supporting tubes and hoses
are in place and properly secured.
Power steering hoses and lines must not be twisted,
kinked or tightly bent. Air in the system will cause
spongy action and noisy operation. W hen a hose is
disconnected or when fluid is lost, for any reason, the
system must be bled after refilling. Refer to Bleeding the
Power Steering System in this section.
・ Inspect gear for looseness or damage.
・ Inspect hoses to insure they are not touching an
y
other parts of the vehicle.
・ Inspect fluid level and fill to the proper level.

Fluid Level
1. Run the engine until the power steering fluid
reaches normal operating temperature, about 55 °
C (130 °F), then shut the engine off.
2. Check the level of fluid in the reservoir.
3. If the fluid level is low, add power steering fluid as
specified in General Information to the proper level
and install the receiver cap.
4. W hen checking the fluid level after the steering system has been serviced, air must be bled from
the system. Refer to Bleeding the Power Steering
System in this section.

Bleeding the Power Steering System
W hen a power steering pump or unit has been installed,
or an oil line has been disconnected, the air that has
entered the system must be bled out before the vehicle
is operated. If air is allowed to remain in the powe
r
steering fluid system, noisy and unsatisfactory operation
of the system may result.

Bleeding Procedure
W hen bleeding the system, and any time fluid is added
to the power steering system, be sure to use only powe
r
steering fluid as specified in General Information.
1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two minutes.
2. Start the engine and let it run for a few seconds. Do not turn the steering wheel. Then turn the engine
off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level remains constant after running the engine.
5. Raise and support the front end of the vehicle so that the wheels are off the ground.
6. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops.
7. Add power steering fluid if necessary.
8. Lower the vehicle, set the steering wheel at the straight forward position after turning it to its full
steer positions 2 or 3 times, and stop the engine.
9. Check the fluid level and refill as required.
10. If the fluid is extremely foamy, allow the vehicle to settle for a few minutes, then repeat the above
procedure.

Flushing the Power Steering System
1. Raise and support the front end of the vehicle off
the ground until the wheels are free to turn.
2. Remove the fluid return line at the pump inlet connector and plug the connector port on the pump.
Direct the line toward a large container to catch the
draining fluid.
3. W hile running the engine at idle, fill the reservoi
r
with new power steering fluid. Turn the steering
wheel in both directions. Do not contact or hold the
steering wheel to the wheel stops. This will cause
the pump to go to pressure relief mode, which ma
y
cause a sudden fluid overflow at the reservoir.


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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-9
4. Install all the lines and hoses. Fill the system with
new power steering fluid and bleed the system as
described in Bleeding the Power Steering System.
Operate the engine for about 15 minutes.
Remove the pump return line at the pump inlet and
plug the connection on the pump. W hile refilling the
reservoir, check the draining fluid for contamination.
If foreign matter is still evident, replace all lines,
disassemble and clean or replace the powe
r
steering system components. Do not re-use any
drained power steering fluid.

Steering Wheel Free Play Inspection
RTW 73BSH000901
1. W ith the tires in the straight-ahead position, check the amount of steering wheel play by turning the
wheel in both directions until the tires begin to move.
NOTE: The wheel free play should be checked with the
engine running. Free play: 0 - 30 mm (0 - 1.18 in)
2.
Also check the steering wheel for play and
looseness in the mount by moving it back and forth
and sideways. W hen test driving, check for hard
steering, steering shimmy and tendency to pull to
one side.

Front End Alignment Inspection and
Adjustment
Toe-in Adjustment
Toe-in: Refer to Section 3A FRONT ALIGNMENT
1. To adjust the toe-in angle, loosen the lock nuts (2) on the tie rod (1) and turn the tie rod. Turn both rods
the same amount, to keep the steering wheel
centered .
431R30006
2. Tighten the lock nut to the specified torque. Torque:
98 N ⋅
⋅⋅
⋅
m (10 kgf ⋅
⋅⋅
⋅
m/72 lb ⋅
⋅⋅
⋅
ft)

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ISUZU KB P190 2007

3B-10 POWER-ASSISTED STEERING SYSTEM
Torque Specification
N⋅m (kgf ⋅m/Ib ⋅ft)

RTW 53BLF001001

Special Tools

ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION

TOOL NO.
TOOL NAME
5-8840-0135-0
(J-29877-A) Tester;
Power steering 5-8840-2297-0
(J-39213) Adapter;
Power steering tester


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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-11
Power Steering Unit
Power Steering Unit and Associated Parts


431R300016
Legend
(1) Crossmember
(2) Power Steering Unit Assembly
(3) Bracket
(4) Universal joint (Steering shaft)


Removal
1. Remove the universal joint assembly. Make a setting mark across the coupling flange and
steering unit to insure reassembly of the parts in the
original position.
2. Drain power steering fluid.

3. Remove the tie rod end assembly from knuckle.
Use tie rod end remover 5-8840-2005-0.


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ISUZU KB P190 2007

3B-12 POWER-ASSISTED STEERING SYSTEM
901RW 270
4. Disconnect the feed line and return line from
steering unit.
Remove the clips on the crossmember and frame.
W ire the power steering line to frame.
NOTE: Take care to prevent foreign matter from
entering when disconnecting the power steering line.
5. Remove the power steering unit from the crossmember.

Installation
1. Install power steering unit on crossmember.
Tighten fixing bolt and nut to specified torque.
Torque:
116 N ⋅
⋅⋅
⋅
m (11.8 kgf ⋅
⋅⋅
⋅
m/85 lb ⋅
⋅⋅
⋅
ft)
Torque:
220 N ⋅
⋅⋅
⋅
m (22.4 kgf ⋅
⋅⋅
⋅
m/162 lb ⋅
⋅⋅
⋅
ft)
2. Connect the feed line and return line. Torque:
25 N ⋅
⋅⋅
⋅
m (2.5 kgf ⋅
⋅⋅
⋅
m/18 lb ⋅
⋅⋅
⋅
ft)
3. Install tie-rod end assembly on knuckle. Torque:
98 N ⋅
⋅⋅
⋅
m (10 kgf ⋅
⋅⋅
⋅
m/72 lb ⋅
⋅⋅
⋅
ft)
4.
Align the setting marks on the universal joint
(applied at disassembly) with the setting marks on
the power steering unit. Connect the universal joint
assembly to the power steering unit.
5. Tighten the universal joint bolt to the specified torque.
Torque:
31 N ⋅
⋅⋅
⋅
m (3.2 kgf ⋅
⋅⋅
⋅
m/23 lb ⋅
⋅⋅
⋅
ft)
6. Install the stone guard.
7. Bleed the system. Refer to Bleeding the Power Steering System in this
section.



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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-13
Power Steering Unit Disassembled View

RTW 53BLF000401
Legend
(1) Tie-rod End
(2) Lock Nut
(3) Clip
(4) Bellows
(5) Band
(6) Tie-rod Assembly
(7) Oil Line
(8) Rack Bar
(9) Tab W asher
(10) Mounting Rubber
(11) Housing Assembly
(12) Dust Cover



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ISUZU KB P190 2007

3B-14 POWER-ASSISTED STEERING SYSTEM
Disassembly
NOTE : The valve hosing is made of aluminum and care
should be exercised when clamping in a vise, etc.
to prevent distortion or damage.
For the left side, follow the same steps as right side.
1. Loosen lock nut and remove tie-rod end.
2. Remove clip and band, then remove bellows.
• Use a pair of pliers to open the clip. Slide the cliptoward the tie-rod end.





RUW 53BSH000401
• Remove band from the bellows by using
screwdriver.





RUW 53BSH000501


CAUTION :
For 4 ×
××
×
2 except High ride suspension models;
The band is not reusable. If removed, it must be
replaced with a new one.
Take care not to damage the bellows during band
removal.
For 4 ×
××
×
4 and 4 ×
××
×
2 High ride suspension models;
The band and bellows are not reusable. If removed,
they must be replaced with a new one.
3. Remove tie-rod assembly.
To remove, move the boot toward the tie-rod end, then remove tab washer.
4. Remove oil line, mounting rubber and dust cover.

Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found during inspection.
Check the following parts.
1. Tie-rod end
2. Lock nut
3. Clip
4. Bellows
5. Band
Tie-Rod End
If looseness or play is found when checked by moving
the end of ball joint at tie-rod end, replace tie-rod end.

Tie-Rod Assembly
If the resistance is insufficient or play is felt when
checked by moving the ball on the tie-rod, replace the
tie-rod assembly.

Rubber Parts
For 4 ×2 except High ride suspension models;
If wear or damage is found during inspection, replace
with new ones.
For 4 ×4 and 4 ×2 High ride suspension models;
Even if wear or damage is not found after removal,
replace with new ones.

Reassembly
1. Install mounting rubber and dust cover (If removed).
2. Install oil line. Torque: 12 N ⋅
⋅⋅
⋅
m (1.2 kgf ⋅
⋅⋅
⋅
m/104 lb ⋅
⋅⋅
⋅
in)


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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-15
3. Install tie-rod assembly with tab washer, then tighten
to specified torque. For 4 ×2 except High ride suspension models;
Torque: 83 N ⋅
⋅⋅
⋅
m (8.5 kgf ⋅
⋅⋅
⋅
m/61 lb ⋅
⋅⋅
⋅
ft)
For 4 ×4 and 4 ×2 High ride suspension models;
Torque: 108 N ⋅
⋅⋅
⋅
m (11.0 kgf ⋅
⋅⋅
⋅
m/80 lb ⋅
⋅⋅
⋅
ft)
After tightening, bend tab washer against width
across flat of inner ball joint.
4. Apply grease to the tie-rod groove. Install bellows on housing assembly.
CAUTION :
Make sure that there are no bulges or dents in the
bellows.
After installation, confirm the small end of the
bellows is inserted into the tie-rod groove.











RUW 53BSH000301

5. Caulk the band using clamp pliers 5-8840-2745-0.
For 4 ×2 except High ride suspension models;
Caulk gap(A): less than 2.0mm(0.08in).
For 4 ×4 and 4 ×2 High ride suspension models;
Caulk gap(A): 2.6 – 3.3mm(0.10 – 0.13in).

CAUTION :
Be sure to use a new band.





RUW 53BSH000601
6. Install clip.
7. Install tie-rod end and tighten lock nut.
Torque:
98 N ⋅
⋅⋅
⋅
m (10 kgf ⋅
⋅⋅
⋅
m/72 lb ⋅
⋅⋅
⋅
ft)


Main Data and Specifications
General Specifications
2W D 4W D
Power steering W ithout W ith
Type Rack and pinion
Rack stroke mm (in) 138 (5.43) 138 (5.43) 152 (5.98)
Steering unit
Lock to lock 4.84 3.38 3.23


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ISUZU KB P190 2007

3B-16 POWER-ASSISTED STEERING SYSTEM
Torque Specifications
N⋅m (kgf ⋅m/Ib ⋅ft)





RTW 73BLF000801

Special Tools

ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION

TOOL NO.
TOOL NAME



5-8840-2005-0
(J-29107)
Tie rod end remover






5-8840-2745-0 Clamp plier


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ISUZU KB P190 2007